Case Study: Forbo Flooring cuts breakdowns and boosts productivity with SSG Insight’s Agility

Forbo Flooring reduces breakdowns and increases productivity with Agility

Forbo Flooring Systems, a manufacturer of linoleum, vinyl and carpet tiles with a 200-strong workforce at its Ripley site, faced chronic equipment failures and poor maintenance visibility: a paper-based system left only about 70% of work requests actioned and plant breakdowns ran at around 90 per month. The new engineering manager sought a simple, data-driven Computerised Maintenance Management System (CMMS) to improve reliability, productivity, product quality, plant availability and inter-departmental communication.

Forbo implemented the web-based Agility CMMS with tailored training and “system champions” (about 15 engineers and 120 operators using the system), giving rapid access to KPIs, visual task status and consistent reporting. Within months logged maintenance actions more than doubled (from ~120 to an average of 383 per month), technical availability rose from 89% to 97%, reactive work swung to about 70% proactive, and breakdowns were reduced to under 20 per month — delivering clear productivity, cost and quality improvements.

Forbo Flooring

Steve Green

Engineering Manager